Cutting temperature and tool flank wear

during turning aluminium matrix

composite in air-water spray
environment
- a Taguchi approach
Paper ID: 311

Presented By:
Amit Chapagain
KIIT, Bhubaneswar
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Introduction

Aluminium matrix composites(AMC) =

Aluminum alloy + Reinforcement
Potential application:-
Automotive industries,
Aerospace industries
Properties:-
High fatigue strength, High young’s
modulus, Improved wear resistance, Low
thermal expansion
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Literature Review

Lin et. al. [1] reported increased tool flank wear on increased cutting speed and feed
during turning AMC PCD inserts in dry environment, Sahoo et. al. [2] and Sahoo &
Pradhan [3] also reported similar results with TiN coated and uncoated WC tool.

Venkatesh et. al. [4] observed built-up edge formation on PCD insert while turning AL
356/ SiC composite, and abrasion by hard sic particles was dominant mode of wear.

Ciftci et. al. [5] studied effect of cutting speed, reinforcement size, reinforcement content
on tool wear during turning AA2014/SiC composite with uncoated and multi layer coated
carbide insert in dry environment.

Das et. al. [6] observed reduced tool wear and cutting temperature in spray cooling
environment than dry environment while turning heat treated AMC with multilayer TiN
coated WC insert. Mishra et al. [7] had reported similar result while turning al7075/SiC
with uncoated carbide inserts.
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Experimental Setup
Work Piece : Al 7075/SiCp (15 wt.% , APS 6.18 µm) MMC,
fabricated by stir cast route and heat treated to T6 condition

Cutting Tool : TiN/TiCN/Al2O3/TiN coated WC inserts

Machining Environment:
Air water spray
environment, at 3 bar
pressure, nozzle distance
of 155 mm from
machining zone

Design of Experiments:
Fig : Experimental setups showing (a) air-water spray
Taguchi L16 Orthogonal setup ; and (b) turning of AMC sample
array
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Experimental Results and Discussion

Expt. No. Cutting Speed, Feed, f Depth of Cut, Cutting Temp. , Tc Tool Flank
V (m/min) (mm/rev) d (mm) (0C) Wear,
Fw (mm)
1 40 0.05 0.2 36.60 0.072
2 40 0.1 0.3 47.57 0.096
3 40 0.16 0.4 52.40 0.123
4 40 0.2 0.5 71.67 0.148
5 106 0.05 0.3 48.13 0.110
6 106 0.1 0.2 55.13 0.132
7 106 0.16 0.5 72.07 0.158
8 106 0.2 0.4 76.73 0.161
9 169 0.05 0.4 59.90 0.137
10 169 0.1 0.5 71.00 0.146
11 169 0.16 0.2 63.00 0.169
12 169 0.2 0.3 74.47 0.176
13 206 0.05 0.5 83.50 0.156
14 206 0.1 0.4 77.83 0.168
15 206 0.16 0.3 74.27 0.176
16 206 0.2 0.2 72.83 0.189
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Fig: Infrared thermal images during (a) Expt. No. 1; (b) Expt. No. 6; (c) Expt. No. 12; and (d) Expt. No. 13

Fig: Images of worn cutting edges after (a) Expt. No. 1; (b) Expt. No. 6; (c) Expt. No. 12; and (d) Expt. No. 16
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Influence of machining process parameters on
Cutting Temperature & Tool Flank Wear
Level Cutting Feed Depth of Level Cutting Feed Depth of
Speed Cut Speed Cut
1 52.06 57.03 56.89 1 0.1097 0.1187 0.1405
2 63.02 62.88 61.11 2 0.1403 0.1355 0.1395
3 67.09 65.44 66.72 3 0.157 0.1565 0.1473
4 77.11 73.92 74.56 4 0.1723 0.1685 0.152
Table: Response table for mean Tc Table: Response table for mean Fw

Fig : Main effects plot for mean Tc Fig : Main effects plot for mean Fw
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Optimization of Cutting Temperature using

Taguchi approach
“Smaller is better” criteria is used for S/N ratio
Maximum value of mean S/N ratio is observed for:-
1st level of V (40 m/min) 1st level of f (0.05 mm/rev)
1st level of d (0.2 mm)
V1-f1-d1 was the combination of optimal parameters
Level Cutting Feed Depth of
Speed Cut
1 -34.08 -34.73 -34.83
2 -35.83 -35.81 -35.51
3 -36.5 -36.24 -36.36
4 -37.73 -37.37 -37.43
Delta 3.65 2.65 2.6
Rank 1 2 3
Table: Response table for mean SN ratios of Tc Fig: Main effects plot for mean SN ratios of Tc
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Optimization of Tool Flank Wear using Taguchi

approach
“Smaller is better” criteria is used for S/N ratio
V1-f1-d1 was the combination of optimal parameters

Level Cutting Feed Depth of

Speed Cut
1 19.5 18.86 17.59
2 17.16 17.54 17.43
3 16.13 16.19 16.71
4 15.3 15.5 16.37
Delta 4.2 3.35 1.22
Rank 1 2 3

Table: Response table for mean SN ratios of Fw Fig: Main effects plot for mean SN ratios of Fw
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Response Surface Models for Cutting

Temperature
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Response Surface Models for Tool Flank

Wear
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Analysis of Variance (ANOVA)

Results of ANOVA for Tc

Source P value % of contribution
V 0.001 47.9
f 0.008 21.9
d 0.005 26.0

Results of ANOVA for Fw

Source P value % of contribution

V 0 56.7
f 0 38.5
d 0.141 2.8
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Conclusion
During the turning Al 7075/SiCp compsoite in air
water spray environment both Tc and Fw increased
with increase in any machining parameters.

Optimal combination of machining process

parameters for both the responses was 40 m/min of
cutting speed, 0.05 mm/rev of feed and 0.2 mm of
depth of cut.

Quadratic response surface models for Tc and Fw

was developed and showed high determination
coefficients (96.54% for Tc and 99.2% for Fw) and
reasonable agreement with their adjusted values.
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References
[1] J.T. Lin, D. Bhattacharyya, C. Lane, Wear 181:183 (1995) 883-888

[2] A.K. Sahoo, S. Pradhan, A.K. Rout, Archives of Civil and Mechanical Engineering 13 (2013)
27-35.

[3] A.K. Sahoo, S. Pradhan, Measurement 46 (2013) 3064-3072.

[4] R. Venkatesh, A.M. Hariharan, N. Muthukrishnan,, Proceedings of the World Congress on

Engineering (2009) London.

[5] I. Ciftci, M. Turker and U. Seker, Materials and Design 25 (2004) 251-255.

[6] D. Das, P.C. Mishra, S. Singh, A.K. Chaubey and B.C. Routara, Int. J. of Industrial
Engineering Computations 9 (2018) 1-14.

[7] P.C. Mishra, D.K. Das, M. Ukamanal, B.C. Routara and A.K. Sahoo, Int. J. of Industrial
Engineering Computations, 6:4 (2015) 445-456